U.S. WHEY INGREDIENTS IN NUTRITION BARS AND GELS

A P P L I C AT IONS

MONOGRAPH

BARS AND GELS

U.S. WHEY INGREDIENTS IN NUTRITION BARS AND GELS

By Kimberlee J. Burrington

Dairy Ingredient Applications Laboratory, Wisconsin Center for Dairy Research, University of Wisconsin-Madison, USA

Editorial contributions by Robert Boutin

Knechtel Laboratories, Skokie, Illinois, USA

The nutraceutical confectionery

market enjoys double-digit

growth and product

diversification continues to

make this category strong and

exciting. Diversification occurs

in many areas including

forms, products and ingredient

benefits. The most recent growth

was found in bar, gel and paste

products formulated with higher

levels of protein, including whey

proteins. These products offer

unique nutritional benefits to

both general or ¡°casual snacker¡±

consumers, as well as those

with specific health, diet, energy

or sports focus.

Whey proteins are essential ingredients

in nutrition bars and they are emerging

as key ingredients in energy gels and

pastes. The mild flavor of whey protein

ingredients makes them compatible

with a wide variety of flavors

and guarantees high consumer

acceptability. Recent advances in

U.S. whey protein ingredients allow

nutraceutical manufacturers to create

products with increased protein levels,

better/cleaner taste, superior texture

stability and a longer shelf life.

This monograph reviews the

processing conditions and

formulations of nutraceutical

confectionery products,

including nutrition bars,

their coating, and energy gels

and pastes.

1

e3.11.1

For example, protein bars¡¯ quality

and shelf life have benefited by the

introduction of specialized hydrolyzed

whey protein mixes.

The use of whey proteins in sports

and snack products delivers the

nutrients shown to positively affect

body composition. Research has

demonstrated that whey proteins

are critical for muscle recovery and

growth. They are also one of the very

few ingredients shown to modulate

the immune functions.

A P P L I C AT IONS MONO GR A P H

NUTRITION BARS

Nutrition bars can be manufactured cold

or baked. The cold-manufactured bars are

made using either an extrusion process

or binders (sugar syrups) that allow the

bar components to stay together in a

set shape. The bars¡¯ texture ranges from

that of granola cereal to chewy nougat.

Often, bars will be coated in chocolate

or other flavors. Whey proteins are key

elements in the formulation of sports and

snack bars given their functionality and

excellent nutritional characteristics. The

characteristics of the ingredients used, as

well as the desired eating qualities, will

determine the processing conditions

chosen for manufacturing a bar. Processing

conditions and formulations are discussed

in the following sections.

COLD-PROCESSED BARS

EXTRUDED BARS

Extruded bars represent one of the most

common type of bars available on the

market. These bars are formulated to be

cold-extruded, and then are often coated

with a compound or chocolate coating.

¡ö

BARS AND GELS

The bar itself typically contains:

? Protein ingredients, oils, flavors, nuts or

other inclusions; vitamins and minerals

are often included.

? Other carbohydrates and/or fibers to add

bulk and/or reduce calories.

? A combination of sugar syrups and sugar

alcohols to keep the water activity below

0.60, to avoid mold or bacterial issues,

and help keep the texture of the bar soft

throughout its shelf life.

? Glycerin, a common ingredient in all

high-protein bars, helps to reduce water

activity, keeps the dough pliable and less

sticky and helps to maintain bar softness

during shelf life.

The ingredients are mixed together to form

a dough. Usually, mixers will be jacketed to

control temperatures and to keep the dough

at a consistency that minimizes stickiness

and retains softness for ease of extrusion.

The dough is then placed in the hopper of

the extruder for forming. As the dough is

extruded out in a rope, it is usually rolled

and then cut to size. The bar sometimes

goes through a drying and coating process

before it is individually packaged. This type

of bar can be expected to have a shelf life

of up to 1 year. Good formulation and

packaging are critical to help maintain

optimal taste and texture during shelf life.

High-Protein Bars

This category of bars contains the

highest levels of protein found in any bar.

Commercial bars are available with up to

50% protein. The challenge lies in delivering

a high level of protein in a bar that also has

good taste and texture. Whey ingredients

like whey protein isolate (WPI), whey protein

concentrate with 80% protein (WPC 80)

and whey protein hydrolysate (alone or in

combination with other milk and vegetable

proteins) are common. A bar containing a

combination of WPI and whey protein

hydrolysate will help to maximize the

protein levels and minimize bar hardening,

which often occurs in high-protein bars.

Because the hydrolyzed whey proteins

do not tend to draw moisture away from

the other ingredients in the bar, adding a

small amount of whey protein hydrolysate

(2-20%) will help to improve the shelf life

by maintaining a softer texture. Many U.S.

whey ingredient manufacturers have

specifically designed their hydrolyzed whey

protein ingredients for bar applications.

Please consult your U.S. supplier for

more information.

Whey protein hydrolysates also offer the

benefits of enhanced absorption in the body

because they are somewhat pre-digested.

Hydrolyzed proteins offer other nutritional

properties such as reducing blood pressure.

A detailed description of the health benefits

of whey proteins is presented in the USDEC

nutrition monograph ¡°Health Enhancing

Properties of Whey Proteins and Whey Fractions,¡±

U.S. Whey Ingredients Composition and Advantages in Bar Applications

available at .

Protein

(%)

Carbohydrate

(%)

Fat

(%)

Minerals

(%)

WPI

90-92

0.5-1

0.5-1

2-3

? Highest protein levels

? Lowest levels of lactose and fat

WPC 80

80-82

4-8

4-8

3-4

? High levels of protein

? Low levels of lactose and fat

WPC with 34 to 79% protein

and modified WPC

34-79

Varies

Varies

Varies

? Cost-effective option to add functional and

nutritional ingredients

? Clean label

Hydrolyzed whey protein (HWP)

and blends of HWP, WPC

and WPI

80-92

Varies

Varies

Varies

? Improves shelf life and raises the protein level

? Clean label

? Faster protein absorption and digestibility

Extruded whey proteins

(whey crisp)

40-80

Varies

Varies

Varies

? Adds textural variety

? Equilibrates moisture over time

1-8

1-6

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